So I recently bought an Access cover for my 2010 DC and installed the left rail no problem. I removed the torx bolt closest to the cab on the right side with a little trouble, but eventually I got it out. The problem was the next three on the right side. They are on so tight that I stripped the torx, and have had no luck removing them with easy-out bits, or by dremeling a flat groove and using a screwdriver. I am going crazy and just want to get the bed cover on at this point, rather than having it sitting in my living room. Does anyone have any advice to get these stubborn bolts out? I don't have access to a any sort of welding, so that is out. Thanks in advance.

But seriously, use a dremel with cutting wheel and slot the tops of the screws so you can back them out with a flat head. I've also used a small chisel, peen a corner into the top of the fastener and gently tap it counterclockwise.

So I recently bought an Access cover for my 2010 DC and installed the left rail no problem. I removed the torx bolt closest to the cab on the right side with a little trouble, but eventually I got it out. The problem was the next three on the right side. They are on so tight that I stripped the torx, and have had no luck removing them with easy-out bits, or by dremeling a flat groove and using a screwdriver. I am going crazy and just want to get the bed cover on at this point, rather than having it sitting in my living room. Does anyone have any advice to get these stubborn bolts out? I don't have access to a any sort of welding, so that is out. Thanks in advance.

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This happened to me. I drilled out ONLY the heads of the bolts then, if you remove the cubby hole boxes (2 on each side of the bed) you can reach up between the fender and bed and turn the bolts out from the back. Take the old bolt to the hardware store and replace them with allen head bolts...I believe the thread is M8x1.00 but you'll need to verify that as it's been awhile.